Subsection of a tower section, a tower and a method for manufacturing a subsection of a tower section

ABSTRACT

A subsection 100 of a tower section comprises a shell segment 120 of the tower section and at least a longitudinal flange 130 mounted to a longitudinal side of the shell segment 120 for connecting to a longitudinal flange of a further subsection of the tower section. Here, the longitudinal flange 130 comprises a part 132 of a surface contour extending from a contact surface 136 of the longitudinal flange 130 which is provided for a connection to a longitudinal flange of a further subsection to a connecting surface 134 connected to the shell segment 120. The part 132 of the surface contour comprises a distance to a contacting plane 106 passing through the contact surface 136.

Examples relate to concepts for manufacturing and constructing towersand subsections of towers and, in particular, to a subsection of a towersection, a tower and a method for manufacturing a subsection of a towersection.

In many fields of technology and construction, members, machines, plantsand systems are used whose components are partially several ten meterslong and may not be decomposed any further for different reasons.Examples come from many different areas and include, for example, towermembers, mechanically particularly stressed carriers, processcontainers, rotor blades for wind turbines, airfoils for aircrafts,drive shafts for watercraft vehicles and other correspondinglongitudinal members, to only mention a few.

In particular when transporting these and similar components frequentlyproblems occur when the respective members are to be transported overland to inland locations or loading locations. Thus, for example, heightlimitations during transport or also problems relating to bend radiusesmay result due to the length of the corresponding members.

During overland transport, for example due to bridge passages maximumpass-through heights may have to be considered. But also due to thelength of the corresponding members of sometimes several ten meters incase of a lying transport a minimum curve radius may frequently not beundercut, which may for example lead to problems when transporting onroads.

In particular for the generation of energy from wind, turbines with hightowers are built. Due to increasing wind speeds at increasing heights,higher yields may be achieved with higher hub heights. In this respect,conventionally wind turbines with tower heights of frequently more than100 m are achieved in steel, concrete, wood or hybrid towers using tubeor lattice construction.

Due to the comparatively low mass and costs, tubular steel towers arepreferred. Due to mass and size limitations on transport paths, suchtowers may not be transported in one piece, however. Consequently,several tower sections with a length of each less than 30 m and anindividual mass of usually less than 100 t are manufactured andconnected to each other at the construction site. Such tower sectionsare usually limited to a diameter of 4.0-4.5 m suitable for bridgepassages.

In particular for large plants such a diameter limitation may not bemade compatible with the occurring loads for a stability check.Consequently it is frequently necessary to increase the diameter atleast in the bottom area of the tower so that a transport as a tubularsection is not possible. Such sections either have to be limitedregarding their length so that they may be transported upright or theyhave to be additionally separated longitudinally. The assembly of atower consisting of several parts may lead to problems in calculationand the proof of stability.

There may be a demand for providing a concept for manufacturing andconstructing towers and subsections of towers so that an improvement ofstability, a facilitated transport and/or a facilitated mounting and/ormanufacturing are enabled.

This demand may be solved by the subject matters of any of the claims.

Some embodiments relate to a subsection (part) of a tower section. Asubsection comprises a shell segment of the tower section and at least alongitudinal flange mounted to a longitudinal side of the shell segmentfor connecting to a longitudinal flange of a further subsection of thetower section. Here, the longitudinal flange comprises a part of asurface contour extending from a contact surface of the longitudinalflange which is provided for a connection to a longitudinal flange of afurther subsection to a connecting surface connected to the shellsegment. The part of the surface contour comprises a distance to acontacting plane passing through the contact surface.

Using the subsections described above or below, the manufacturing and/orthe transport of tower sections may be substantially facilitated, as theshell of the tower section may simply be divided into several partsalong the longitudinal flanges in the factory and then be assembledagain at the setup location comprising basically the same geometry.

A tower section is e.g. a part of a tower which, for example, comprisesa symmetry with respect to a substantially vertical tower axis. Forexample, the tower section (the shell of the tower section) maybasically comprise a cylinder barrel-shaped or truncated conejacket-shaped geometry.

The subsection of the tower section is, for example, generated whenseparating the shell of the tower section into smaller parts.Accordingly, the subsection includes a segment of the shell of the towersection. The shell segment for example includes two basicallyhorizontally (or orthogonally to a tower axis or symmetry axis of thetower section) extending transverse sides and two longitudinal sidesextending basically orthogonally to the transverse sides (e.g. basicallyvertically or towards the tower axis). The longitudinal sides e.g. forhollow cylinder-shaped tower sections may basically be parallel to thetower axis or slightly deviate from the parallel direction for hollowtruncated cone-shaped tower sections (e.g. by less than 3° or less than1°). The shell segment may e.g. comprise a form which basically formspart of a cylinder barrel-shaped or truncated cone jacket-shapedgeometry. The shell segment is for example part of the outer shell ofthe tower and may e.g. be made of steel. The transverse side of theshell segment may for example comprise a length of more than 4 m (ormore than 6 m or more than 8 m). The longitudinal side of the shellsegment may e.g. comprise a length of more than 5 m (or more than 10 mor more than 20 m). The shell segment may for example comprise athickness of more than 25 mm (or more than 35 mm or more than 50 mm).

The subsection of the tower section further includes at least alongitudinal flange. The longitudinal flange is mounted to alongitudinal side of the shell segment (e.g. by a welding seam). Thelongitudinal flange may be mounted to an exterior side or interior sideof the shell segment.

Below the surface contour of the longitudinal flange for example theshape of the complete surface of the longitudinal flange may beimminent. For example, the contact surface of the longitudinal flangewhich is provided for a connection to a longitudinal flange of a furthersubsection and the connecting surface via which the longitudinal flangeis connected to the shell segment are part of the surface contour. Thecontact surface is for example a basically flat surface which is indirect contact with the longitudinal flange of a further subsection whenassembling the tower section from several subsections.

In one part extending from a contact surface of the longitudinal flangewhich is provided for a connection to a longitudinal flange of a furthersubsection to the connecting surface connected to the shell segment, thesurface contour comprises a distance to the contacting plane passingthrough the contact surface. The contacting plane is e.g. a virtualplane substantially (e.g. neglecting unevennesses of the contactsurface) passing through the contact surface of the longitudinal flange.The distance to the contacting plane may for example increaseerratically, continuously, linearly or in any different way from thecontact surface towards the shell segment. For example, the part of thesurface contour of the longitudinal flange arranged between the contactsurface and the connecting surface may comprise a distance of more than1.5 mm (or more than 3 mm or more than 5 mm) to an end adjacent to theconnecting surface connected to the shell segment. Due to the distanceto the contacting plane, for example, a gap results between the end ofthe longitudinal flange and the longitudinal flange of a furthersubsection when the subsections are connected to each other. Due to thedescribed surface contour, for example the arrangement of a spacermember between two longitudinal flanges of subsections to be connectedmay be avoided. The longitudinal flange of the subsection may beimplemented in one piece. In this way subsections with a low number ofmembers may easily be manufactured.

For example, the part of the surface contour of the longitudinal flangearranged between the contact surface and the connecting surface forms anotch or an undercut-shaped recess. An undercut-shaped recess forexample hast basically the same geometry as an undercut but thelongitudinal flange is not a rotation-symmetric member as it is usuallythe case with an undercut.

The longitudinal flange may for example have a smaller thickness at anend facing the shell segment than in an area of the contact surface.Alternatively, the longitudinal flange may be bent away from thecontacting plane between the contact surface and the connecting surfaceand comprise a substantially constant thickness.

It may be sufficient to use only a longitudinal flange of the subsectionwith the described surface contour. Alternatively, a longitudinal flangeeach with the described surface contour may be arranged at bothlongitudinal sides of the shell segment.

The longitudinal flange may extend across the complete longitudinal sideof the shell segment of the subsection. Alternatively, the longitudinalflange may be shorter than the longitudinal side of the shell segmentsuch that at least at the ends of the longitudinal side no longitudinalflange extends (e.g. along at least the last 10 cm, at least the last 30cm or at least the last 50 cm). By this, mounting a transversal flangealong a transverse side of the shell segment of the subsection may befacilitated.

The subsection may optionally comprise a basically circle segment-shapedtransversal flange. The transversal flange may be mounted to atransverse side of the shell segment of the subsection. Further,optionally also on both transverse sides of the shell segment of thesubsection one transversal flange each may be mounted. The transversalflange may be used to connect the subsection of a different towersection, a subsection of a different tower section or a foundation (e.g.by screws).

Optionally, in the shell segment of the subsection a door opening may beprovided.

More details and optional aspects of the described subsection of thetower section are mentioned in connection with the proposed concept orone or more embodiments described in the following (e.g. FIGS. 1 to 6).

Some embodiments relate to a tower with a plurality of tower sections.Here, at least one tower section comprises at least two subsections,according to any of the embodiments above or below. The longitudinalflange of a first subsection of the at least two subsections is directlyconnected to a longitudinal flange of a second subsection of the atleast two subsections. Further, between the shell segment of the firstsubsection and the shell segment of the second subsection a gap exists.

E.g. a vertically aligned building is designated as a tower, for examplefor a wind turbine. The definition of a tower contains both braced andalso free-standing constructions and consequently also considersconstructions which are sometimes referred to as a mast. For example,the tower may be a tower of a wind mill.

In the gap between the shell segment of the first subsection and theshell segment of the second subsection a sealing element (e.g. aT-shaped sealing element) may be arranged.

More details and optional aspects of the described tower are mentionedin connection with the proposed concept or one or more embodimentsdescribed above or below (e.g. FIGS. 1 to 6).

Some further embodiments relate to a method for manufacturing at least asubsection of a tower section. The method comprises mounting twoneighboring, one-piece longitudinal flanges to a shell of a towersection, so that the two neighboring, one-piece longitudinal flanges aredirectly in contact with one another along a contact surface. Further,the method comprises separating the shell at least along the twoneighboring, one-piece longitudinal flanges. Here, at least afterseparating at the two neighboring, one-piece longitudinal flanges a gapexists between the ends of the two neighboring, one-piece longitudinalflanges facing the shell.

Due to the possibility of generating a gap during separation or due tothe existence of a gap already before separation separating the shell ofthe tower section may be clearly facilitated.

The longitudinal flanges may for example be connected to the shell bywelding. It may be sufficient here to provide a welding seam at one sideeach facing away from the respective other longitudinal flange.Optionally, after separating, also on the opposite side a welding seammay be provided. The optional welding seam on the opposite side may beenabled by the existing gap as there is for example sufficient room forthe welding seam due to the gap.

The longitudinal flanges are mounted to the shell so that the contactsurfaces of the longitudinal flanges are in direct contact with oneanother. Thus, for example, an intermediate member or spacer member isarranged between the longitudinal flanges.

The gap between the ends of the two neighboring one-piece longitudinalflanges may already exist after mounting and before separating at theends of the two neighboring one-piece longitudinal flanges facing theshell. In this respect, one or both of the neighboring, one-piecelongitudinal flanges may for example comprise a surface contour asdescribed above or illustrated in the following figures. The ends of thetwo longitudinal flanges are for example those parts of the longitudinalflanges which are arranged closer than 5 cm or closer than 2 cm orcloser than 1 cm to the shell. For example the gap between the twoneighboring longitudinal flanges may be larger than a gap generated bythe separation between the at least two shell segments. By this, forexample, the shell may be separated without damaging the longitudinalflanges by the separating tools.

For example, the gap between the two neighboring longitudinal flangesmay be more than 5 mm (or more than 1 cm or more than 2 cm) larger thanthe gap between the shell segments of the at least two subsections. Thegap between the ends of the two neighboring longitudinal flanges may forexample be larger than 3 mm (or larger than 6 mm or larger than 1 cm)and/or smaller than 5 cm (or smaller than 2 cm). The gap between theshell segments of the at least two subsections may for example be largerthan 1 mm (or larger than 2 mm or larger than 5 mm) and/or smaller than1 cm (or smaller than 5 mm).

Alternatively, the shell may be separated so that the gap exists betweenthe ends of the two neighboring, one-piece longitudinal flanges afterseparating at the ends of the two neighboring, one-piece longitudinalflanges facing the shell. Here, for example, the separating tool (e.g. asaw) cuts through the shell down into the longitudinal flanges. Thelongitudinal flanges may comprise a larger thickness than a gapgenerated by the separation, so that the gap between the generated shellsegments may extend into the longitudinal flanges.

The two neighboring longitudinal flanges may be connected to each otherby a detachable connection during the separation of the shell (e.g.screws or stitching together by weld technique). The subsections of thetower section may be separated from each other by detaching theconnection and be provided to the location of assembly separately. Atthe location of assembly the subsections may again be connected to eachother via the longitudinal flanges.

More details and optional aspects of the described methods are mentionedin connection with the proposed concept or one or more embodimentsdescribed above or below (e.g. FIGS. 1 to 6).

In the following, with reference to the accompanying figures, examplesare described and explained in more detail.

FIG. 1A shows a schematic illustration of a subsection of a towersection;

FIG. 1B shows a schematic illustration of an interconnect location oftwo subsections of a tower section;

FIG. 2 shows a schematic cross section of a wind turbine;

FIG. 3 shows a flow chart of a method for manufacturing a subsection ofa tower section;

FIG. 4A shows a schematic partial view of a longitudinal flange beforeconnecting the same to a shell of a tower section;

FIG. 4B shows schematic view of an end of a tower section after mountingtwo neighboring longitudinal flanges and before separating the shell;

FIG. 4C shows a schematic cross section of two neighboring longitudinalflanges before separating the shell;

FIG. 4D shows a schematic view of an end of a tower section afterseparating the shell;

FIG. 4E shows a schematic view of a subsection of a tower section;

FIG. 4F shows a schematic view of a detail of the tower section of FIG.4E;

FIG. 4G shows a schematic cross section of two neighboring longitudinalflanges after separating the shell;

FIG. 5A-5D show examples for schematic cross sections of differentimplementations of neighboring longitudinal flanges before separatingthe shell;

FIG. 6 shows a schematic cross section of two neighboring longitudinalflanges when separating the shell;

FIG. 7 shows a flow chart of a method for manufacturing a tower section;and

FIG. 8A-8I show schematic cross sections of parts of a tower section atdifferent stages during the manufacturing of the tower section.

Some examples are described now in more detail with reference to theaccompanying figures. In the figures, the thicknesses of lines, areas,layers and/or regions may be exaggerated for clarity.

Like reference signs refer to like or similar components throughout thefollowing description of the included figures, which merely show someexemplary embodiments. Moreover, summarizing reference signs will beused for components and objects which occur several times in one exampleor in one figure but are described commonly with respect to one orseveral features. Components and objects described with like orsummarizing reference signs may be implemented alike or alsodifferently, if applicable, with respect to one or more or all thefeatures, e.g. their dimensioning, unless explicitly or implicitlystated otherwise in the description.

Although examples may be modified and changed in different ways, onlysome examples are presented in detail in the figures and in the presentdescription. It is to be clarified, however, that is not the object torestrict examples to the respectively disclosed forms, but to thecontrary, that examples are to cover all structural modifications,equivalents, and alternatives falling within the scope of the invention.Same reference numerals designate same or similar elements throughoutthe complete description of the figures, as explained above.

FIG. 1A shows a schematic illustration of a subsection 100 of a towersection. The subsection 100 of the tower section comprises a shellsegment 120 of the tower section and at least a longitudinal flange 130mounted to a longitudinal side of the shell segment 120 for connectingto a longitudinal flange 150 of a further subsection 102 of the towersection. Here, the longitudinal flange 130 comprises a part 132 of asurface contour extending from a contact surface 136 of the longitudinalflange 130 which is provided for a connection to a longitudinal flangeof 150 a further subsection 102 to a connecting surface 134 connected tothe shell segment 120. The part 132 of the surface contour comprises adistance to a contacting plane 106 passing through the contact surface136.

The part 132 of the surface contour for example has an increasingdistance from the contact surface 136 provided for a connection to thelongitudinal flange 150 of the further subsection 102 to the connectingsurface 134 connected to the shell segment 120.

For example, the longitudinal flange 130 comprises a smaller thicknessat an end facing the shell segment 120 than in an area of thelongitudinal flange 130 which is in contact with the longitudinal flange150 of the further subsection 102 when connecting to the longitudinalflange 150 of the further subsection 102.

More details and optional aspects of the subsection of the tower sectionillustrated in FIG. 1A are mentioned in connection with the proposedconcept or one or more embodiments described above or below (e.g. FIGS.2 to 6).

FIG. 1B shows a schematic illustration of an interconnect location oftwo subsections 100, 102 of a tower section. The subsections 100, 102each comprise a shell segment 120, 140 and at least one longitudinalflange 130, 150. The longitudinal flanges 130, 150 comprise holes 138for connecting the longitudinal flanges (e.g. by screws). Further,between the ends of the longitudinal flanges 130, 150 facing the shellsegments 120, 140 a gap exists. Likewise, between the two shell segments120, 140 a gap is arranged. Additionally, in the gap between the shellsegments 120, 140 a substantially T-shaped sealing element is arrangedfor sealing the gap.

For example, FIG. 1B shows a situation after the assembly (screws notillustrated).

More details and optional aspects of the subsection of the tower sectionillustrated in FIG. 1B are mentioned in connection with the proposedconcept or one or more embodiments described above or below (e.g. FIGS.2 to 6).

FIG. 2 shows a schematic cross section of a wind turbine 200 accordingto an embodiment. The wind turbine 200 comprises a tower and a machinehouse 230 with a connected rotor 240. The tower includes a hollowtruncated cone-shaped lower tower section 210 and three hollowcylindrical top tower sections 220. At least the lower tower section 210includes two subsections as described in the above described concept orin connection with one or more embodiments described above or below(e.g. FIGS. 1 or 3 to 4G). For example, the subsections and/or towersections may be connected to each other by screwing or by a weldingmethod at the location of assembly.

More details and optional aspects of the tower or a tower section arementioned in connection with the proposed concept or one or moreembodiments described above or below (e.g. FIGS. 1 or 3 to 4G).

FIG. 3 shows a flow chart of a method for manufacturing at least onesubsection of a tower section. The method 300 comprises mounting 310 twoneighboring, one-piece longitudinal flanges to a shell of a towersection, so that the two neighboring, one-piece longitudinal flanges aredirectly in contact with one another along a contact surface. Further,the method comprises separating 320 the shell at least along the twoneighboring, one-piece longitudinal flanges. Here, at least afterseparating, at the two neighboring, one-piece longitudinal flanges a gapexists between the ends of the two neighboring, one-piece longitudinalflanges facing the shell.

More details and optional aspects of the method 300 are mentioned inconnection with the proposed concept or one or more embodimentsdescribed above or below (e.g. FIG. 1 to 2 or 4A to 4G).

FIG. 4A shows a schematic partial view of a longitudinal flange 130before connecting the same to a shell 120 of a tower section. In thisrespect, the longitudinal flange is arranged at a designated positionalong the shell 120 (here only part of the shell is shown which extendsfurther than illustrated in FIG. 4A before separating) and will forexample be connected to the shell 120 at a location 434 arranged at aside facing away from the contact surface 136 of the longitudinal flangeby a welding seam. The longitudinal flange in FIG. 4 is arranged at theinterior side of the shell 120, but may alternatively also be arrangedat an exterior side of the shell 120. Optionally, after separating, afurther welding seam may be generated at a location 432 arranged at aside facing the contact surface 136 of the longitudinal flange betweenthe longitudinal flange and the shell 120.

For example, FIG. 4A shows a position of one half of the longitudinalflange with respect to a longitudinal member of the tower.

FIG. 4B shows schematic view of an end of a tower section after mountingtwo neighboring longitudinal flanges 130 and before separating the shell120. The longitudinal flanges 130 are for example connected to eachother by screws 438 and may be disconnected again after separating theshell 120. At the top and/or bottom end of the shell 120 of the towersection transversal flanges 460 may be arranged for connecting to othertower sections or to a foundation. The transversal flanges 460 may beseparated into several parts across the circumference of the towersection. For example, the transversal flanges 460 are divided at thesame locations at which the shell 120 is separated along thelongitudinal flanges 130. The transversal flanges 460 may comprise holes462 for a later connection to other tower sections or to a foundation byscrews.

For example, FIG. 4B shows an inclined view after screwing and weldingthe longitudinal flanges before separating the tower shell.

FIG. 4C shows a schematic cross section of two neighboring longitudinalflanges 130 before separating the shell 120. The two longitudinalflanges 130 are connected to the shell 120 via a welding seam 435.Further, the longitudinal flanges are connected to each other by screws438. The longitudinal flanges 130 comprise undercut-shaped recesses attheir ends facing the shell 130 so that between the longitudinal flanges130 in the area of the shell 120 a gap 402 exists. The shell 120 maythus for example be separated along the gap (e.g. by a saw) withoutdamaging the longitudinal flanges 130.

For example, FIG. 4C shows a cut after screwing and welding thelongitudinal flanges 130 before separating the tower shell.

FIG. 4D shows a schematic view of an end of a tower section afterseparating the shell 120. By separating along the longitudinal flanges130 a gap 404 results between the shell segments 120. The gap 404between the shell segments 120 is for example smaller than or of thesame width as a gap between the longitudinal flanges 130 at their endsfacing the shell segments.

For example, FIG. 4D shows an inclined view after separating the towershell.

FIG. 4E shows a schematic view of a subsection of a tower section. Forexample, FIG. 4E shows an area of the divided tower shell 120 withcompletely welded longitudinal flanges 130.

FIG. 4F shows a schematic view of a detail of the tower section of FIG.4E. After separating, the longitudinal flange 130 may be provided with awelding seam 433 also at the side with the undercut-shaped recess toimprove the mounting of the shell 120. The longitudinal flange may endat a defined distance (e.g. more than 10 cm, more than 30 cm or morethan 50 cm) to a top and/or bottom end of the longitudinal side of theshell 120, for example to facilitate a simple mounting of thetransversal flange 460.

For example, FIG. 4F shows an enlargement of an area of the dividedtower shell with completely welded longitudinal flanges (longitudinalseam visible in the area of the cutting surface).

FIG. 4G shows a schematic cross section of two neighboring longitudinalflanges 130 after separating the shell 120. By separating the shell 120a gap results between the shell segments 120. Due to the undercut-shapedrecesses 132 at the ends of the longitudinal flanges 130 the shell maybe separated without damaging the longitudinal flanges 130 duringseparation. The subsections of the tower section may be separated fromeach other by detaching the screws 438 at the longitudinal flanges 130and be provided to the location of assembly separately. At the locationof assembly the subsections may again be connected to each other via thelongitudinal flanges 130. It is further possible, after separating anddetaching the screws, to apply an additional welding seam, wherein thesection may again be assembled in the same way.

For example, FIG. 4G shows a cross-section after the assembly, without arepresentation of the seal.

FIGS. 5A-5D show examples for schematic cross sections of differentimplementations of neighboring longitudinal flanges 130 beforeseparating the shell 120 (e.g. alternatives to the example shown in FIG.4C).

FIG. 5A shows a schematic cross section of neighboring longitudinalflanges 130 before separating the shell 120. Here, the part 132 of thesurface contour shows an erratic increase of the distance to thecontacting plane from the contact surface between the longitudinalflanges 130 to the connecting surface with the shell 120. In otherwords, in cross-section the longitudinal flanges 130 comprise a squareor rectangular recess, so that a rectangular or square gap existsbetween the longitudinal flanges already before the separation.

FIG. 5B shows a further schematic cross section of neighboringlongitudinal flanges 130 before separating the shell 120. Here, the part132 of the surface contour shows a linearly increasing distance to thecontacting plane from the contact surface between the longitudinalflanges 130 to the connecting surface with the shell 120. In otherwords, in cross-section the longitudinal flanges 130 comprise atriangular, wedge-shaped or notch-shaped recess, so that a triangulargap exists between the longitudinal flanges already before theseparation.

FIG. 5C shows a further schematic cross section of neighboringlongitudinal flanges 130 before separating the shell 120. Here, the part132 of the surface contour shows an increasing distance to thecontacting plane from the contact surface between the longitudinalflanges 130 to the connecting surface with the shell 120. Incross-section the longitudinal flanges 130 comprise a quadrant-shaped orquarter ellipsis-shaped recess, so that a quadrant-shaped or quarterellipsis-shaped gap exists between the longitudinal flanges alreadybefore the separation.

FIG. 5D shows a further schematic cross section of neighboringlongitudinal flanges 130 before separating the shell 120. Here, the part132 of the surface contour shows an initially increasing and thenconstant distance to the contacting plane from the contact surfacebetween the longitudinal flanges 130 to the connecting surface with theshell 120. In cross-section the longitudinal flanges 130 comprise aninitially quadrant-shaped or quarter ellipsis-shaped recess, so thatinitially a quadrant-shaped or quarter ellipsis-shaped gap existsbetween the longitudinal flanges already before the separation whichthen extends basically in parallel to the contacting plane to the shell120. By this, for example, a deeper gap in comparison to FIG. 5C may begenerated.

The gap illustrated in FIGS. 5A-5D exists again at the completelyassembled tower, for example, as the two neighboring longitudinalflanges are only separated for transport and connected again at thelocation of assembly.

FIG. 6 shows a schematic cross section of two neighboring longitudinalflanges 130 when separating the shell 120. In this example, thelongitudinal flanges 130 show no gap yet in the area of the shell 120before separating the shell 120. The gap between the longitudinalflanges 130 is only generated by separating the shell. The twolongitudinal flanges 130 comprise a clearly larger (e.g. more than 1.5times larger or more than two times larger or more than 3 times larger)common thickness (sum of the thicknesses of the two longitudinalflanges) than a thickness of the separating tool 600 or a thickness ofthe gap resulting from the separation. The longitudinal flanges 130 arefor example mounted to the shell 120 by welding seams. The longitudinalflanges may optionally comprise skewed ends to obtain a more stablewelding connection to the shell 120.

FIG. 7 shows a flow chart of a method for manufacturing a tower sectionaccording to one embodiment. The method 700 includes (permanently)mounting 710 a first one-piece longitudinal flange for a firstsubsection of a tower section to a shell of the tower section anddetachably connecting 720 a second one-piece longitudinal flange for asecond subsection of the tower section to the first one-piecelongitudinal flange for the first subsection after mounting the firstone-piece longitudinal flange for the first subsection to the shell ofthe tower section, so that the two neighboring, one-piece longitudinalflanges are directly in contact with one another along a contactsurface. Further, the method 700 comprises (permanently) mounting thesecond one-piece longitudinal flange for the second subsection of thetower section to the shell of the tower section, after detachablyconnecting the second one-piece longitudinal flange for the secondsubsection of the tower section to the first one-piece longitudinalflange for the first subsection. Additionally, the method 700 comprisesseparating the shell at least along the two neighboring, one-piecelongitudinal flanges, wherein at least after separating a gap exists atthe two neighboring, one-piece longitudinal flanges between the ends ofthe two neighboring, one-piece longitudinal flanges facing the shell.

Due to the possibility of generating a gap during separation or due tothe existence of a gap already before separation separating the shell ofthe tower section may be clearly facilitated. Further, by the detachableconnection after mounting the first longitudinal flange to the shell andbefore mounting the second longitudinal flange to the shell, the twolongitudinal flanges may be attached to the shell better and more flushas compared to when the longitudinal flanges are already connected toeach other before mounting the first longitudinal flange to the shell.

The gap between the ends of the two neighboring one-piece longitudinalflanges may already exist after mounting 730 the second one-piecelongitudinal flange and before separating 740 at the ends of the twoneighboring one-piece longitudinal flanges facing the shell.Alternatively, the shell may be separated so that the gap exists afterseparating 740 between the ends of the two neighboring, one-piecelongitudinal flanges at the ends of the two neighboring, one-piecelongitudinal flanges facing the shell.

For example, the method may further include detaching the detachableconnection between the two neighboring, one-piece longitudinal flangesfor a transportation to a destination of the tower. For manufacturingthe tower with the tower section, the first and the second subsection ofthe tower section may be transported to a destination or location ofassembly of the tower after detaching the detachable connection. At thedestination or location of assembly of the tower, the first subsectionand the second subsection may again be connected (e.g. by screws)detachably to each other via the first one-piece longitudinal flange ofthe first subsection and the second one-piece longitudinal flange of thesecond subsection

For example, before mounting to the shell, the one-piece longitudinalflange for the first subsection (and/or the longitudinal flange for thesecond subsection) comprises a part of a surface contour extending froma contact surface of the longitudinal flange of the first subsectionwhich is provided for a connection to the longitudinal flange of thesecond subsection to a connecting surface connected to the shell of thetower section. The part of the surface contour for example comprises adistance to a contacting plane passing through the contact surface.Optionally, when mounting to the shell, the one-piece longitudinalflange for the first subsection may be mounted to the shell by a weldingseam at a side facing away from the second longitudinal flange and/or ata side facing the second longitudinal flange. Further, during mountingto the shell, the one-piece longitudinal flange for the secondsubsection may be mounted to the shell by a welding seam at a sidefacing away from the first longitudinal flange. Optionally, afterseparating the shell and after detaching the detachable connection, theone-piece longitudinal flange of the second subsection may additionallybe mounted to the shell by a welding seam at a side facing the firstlongitudinal flange.

More details and aspects are mentioned in connection with theembodiments described above or below. The embodiment shown in FIG. 7 maycomprise one or more optional additional features corresponding to oneor more aspects mentioned in connection with the proposed concept or oneor more embodiments described above (e.g. FIG. 1-6) or below (e.g. FIG.8A-8I).

FIG. 8A-8I show schematic cross sections of parts of a tower section atdifferent stages during the manufacturing of the tower section accordingto one embodiment.

FIG. 8A shows a schematic partial view of a first one-piece longitudinalflange 130 after connecting the same to a shell 120 of a tower section.In this respect the first longitudinal flange 130 is arranged at adesignated position along the shell 120 and for example mounted to alocation at the shell 120 (longitudinal flange 1 weld in, exteriorposition) arranged at a side facing away from the contact surface of thelongitudinal flange (for abutting a second longitudinal flange) by awelding seam 435. The longitudinal flange in FIG. 8A is arranged at theinterior side of the shell 120 but may alternatively also be arranged atan exterior side of the shell 120. The first longitudinal flangecomprises holes 138 for a connection to a second longitudinal flange.Further, the first longitudinal flange comprises an (undercut-shaped ornotch-shaped) recess or taper 132 at an end facing the shell 120.Optionally, a further welding seam 435 may be generated at a locationbetween the longitudinal flange and the shell 120 arranged at a sidefacing the contact surface of the longitudinal flange, as illustrated inFIG. 8B (longitudinal flange 1 welding counter-layer)

Afterwards a second one-piece longitudinal flange 150 of a secondsubsection of the tower section is detachably connected to the firstone-piece longitudinal flange 130 of the first subsection after mountingthe first one-piece longitudinal flange 130 of the first subsection tothe shell of the tower section, so that the two neighboring, one-piecelongitudinal flanges are directly in contact with one another along thecontact surface, as illustrated in FIG. 8C. The detachable connectionmay for example be generated by screws 438 extending through the holes138 in the longitudinal flanges (screw longitudinal flanges 1 and 2).

After detachably connecting the second one-piece longitudinal flange 150of the second subsection of the tower section to the first one-piecelongitudinal flange 150 of the first subsection, the second one-piecelongitudinal flange 150 of the second subsection of the tower sectionmay be mounted to the shell 120 of the tower section (e.g. via a weldingseam at a side of the second longitudinal flange 150 facing away fromthe first longitudinal flange 130), as illustrated in FIG. 8D (weldlongitudinal flange 2 exterior layer).

After mounting the second longitudinal flange 150 to the shell 120, theshell may be separated into at least two subsections (e.g. by sawing)along the two neighboring one-piece longitudinal flanges, as illustratedin FIG. 8E. As between the two longitudinal flanges at their end facingthe shell 120 a gap already exists, separating may take place easily andwithout damaging the longitudinal flanges. Also after separating at thetwo neighboring, one-piece longitudinal flanges a gap exists between theends of the two neighboring, one-piece longitudinal flanges facing theshell 120.

After separating the shell 120 into at least two shell segments and theconsequently executed separation of the tower section into twosubsections, the detachable connection of the two longitudinal flangesmay be detached again as illustrated in FIG. 8F (detach screws andseparate tower halves).

The at least two subsections may then be separated from each other asillustrated in FIG. 8G and be transported to the destination or locationof assembly of the tower separately. Before that, optionally afterseparating the shell, at a side of the second longitudinal flange 130which had before been facing the first longitudinal flange 130, thesecond longitudinal flange may be connected to the shell segment 120 ofthe second subsection by an additional welding seam 435 as illustratedin FIG. 8H (weld counter-layer of longitudinal flange 2).

After transport to the destination or location of assembly of the towerthe at least two or more subsections of the tower section may again beassembled into one complete tower section by again connecting oppositelongitudinal flanges (e.g. first and second longitudinal flange) (e.g.by screws), as illustrated in FIG. 8I.

Some embodiments relate to a tower section and methods for manufacturinga tower section.

A tower for wind energy plants may for example be presented particularlyeconomically, if as few segments as possible are used with as little useof material. This may for example be achieved with respect to windturbines with high hub heights if, for example, only the lower towersegment is separated longitudinally with as little effort as possible,for example by machining. To be able to guarantee stability, the partsof such a tower section have to be connected again after transport, e.g.by longitudinal flanges.

By simply separating the tower wall, as a consequence of removingmaterial a gap results. Closing same without further measures might leadto a non-circular cross-section of the tower which may lead to problemswhen calculating and proving stability.

For example, for reasons of proving stability but also for reasons ofmanufacturing, longitudinal flanges may be welded. Would the same beapplied after separating such a tower section, deformations of the towerstructure may result due to heat input. If the flange pairs are alreadyapplied before separation, they may be damaged by the separationprocess. If the flange pairs are held at a distance by a spacer in orderto generate a gap, the tower may later only be put together using thisspacer which would cause additional costs.

According to the proposed concept, with an undercut in the area of thelongitudinal flange pairs an improvement of stability, facilitatedtransport and/or easier assembly and/or manufacturing may be enabled. Itmay thus be possible to realize the tower so that material removedduring manufacturing may be filled up by using a sealant or sealingelement and so that the longitudinal flange pairs are in direct contactwithout them being damaged when separating the tower shell.

For example, based on the proposed concept an undercut-shaped recess ora gap may be used which may e.g. serve as a welding seam preparation fora welding layer at the connection longitudinal flange—interior of towershell to be applied after separating, which may serve as a supportregarding orientation during separation and/or enable a completeseparation without additional members (e.g. spacers).

The gap (undercut-shaped recess) may for example be generated in twodifferent ways, either before separating or by separating. The same maytake on different shapes, e.g. circular, rectangular, triangular with anadditional phase or result from the shape of the cutting tool.

Background is, for example, the rework regarding corrosion protection.If the gap is generated before separating, this way e.g. at the interiora welding seam may be applied without the longitudinal flangesdiverging. If the gap is generated by the separation, a completeseparation may be possible without excessive requirements set withrespect to operating accuracy. As the welding seam between thelongitudinal flange and the shell may be completely welded through, e.g.no additional reworks are required (e.g. apart from sealing in case ofall variants for protecting the gap in the shell).

E.g., a longitudinal flange may be applied by welding. The interior seammay be applied subsequently. Further, a separation of the tower sectionmay be executed by dividing the conical/cylindrical tube from theoutside by sawing, milling, lasing, water jet cutting, burn-cutting oreroding. Here, the tower may be held together by screwed longitudinalflanges. The gap resulting from the separation may be smaller than theexisting gap at the longitudinal flanges (due to the undercut-shapedgeometry of the flanges) to form a space for the separating tool. Forexample, the gap may be approx. 5-20 mm. Further, the separated towersection may be sealed. For example, a sealant (e.g. deformable plasticslike silicone) may be applied in the area of the transversal flangesand/or a T-profile of plastics or the like may be used for sealing thegap of the longitudinal flange.

Some embodiments relate to a hollow cylindrical or hollow truncatedcone-shaped tower section comprising at least two components of bigvolume connected to each other by longitudinal flange pairs wherein thecomponents together form the outer shell of the tower section and areconnectable to a foundation and/or to a further tower section via atleast one ring flange and/or at least one ring flange segment. The outershell may here comprise at least one gap in the area of the longitudinalflange pairs. Further, the longitudinal flange pairs may each comprisean undercut-shaped recess and the longitudinal flanges may be connectedto each other in direct contact by connecting means.

According to one aspect, the at least one gap in the outer shell may befilled up by at least one sealant in the area of the longitudinalflanges. For example, the sealant may comprise at least one T-profile.

According to a further aspect, the connection of the longitudinal flangepair may comprise at least one screw connection.

Optionally, the longitudinal flange pairs may end towards the at leastone ring flange and/or the at least one ring flange segment. Optionally,the tower section may also comprise several one-piece longitudinalflanges which are adjacent to each other in a longitudinal direction.

The tower section may optionally comprise a door opening.

Some embodiments relate to a method for manufacturing a hollowcylindrical or hollow truncated cone-shaped tower section (e.g.according to one of the above described examples). The method includes,for example, manufacturing a tower shell with the shape of a hollowcylindrical or hollow truncated cone-shaped tube having at least oneattached ring flange component and joining at least two longitudinalflange pairs connected to each other in direct contact which compriseand undercut-shaped recess or a gap with the hollow cylindrical orhollow truncated cone-shaped tube. Further, the method may compriseseparating the tower shell into at least two components and detachingthe longitudinal flange pairs. The at least two components may beconnected at the set-up location of the tower.

Optionally, manufacturing the tower shell may include at least onerolling process and joining the at least one ring flange component mayinclude at least one welding process.

According to one aspect, the at least one ring flange component may beseparated into at least two parts before manufacturing the hollowcylindrical or hollow truncated cone-shaped tube.

Optionally, before and/or after manufacturing a tower shell, at leastone longitudinal flange pair comprising an undercut-shaped recess or agap, may be connected in direct contact by screwing, riveting, jammingor welding.

Additionally, manufacturing the tower shell may include at leastpartially applying corrosion protection.

According to one aspect, joining the at least two longitudinal flangepairs connected to each other in direct contact with the hollowcylindrical or hollow truncated cone-shaped tube may include welding.Here, welding the at least two longitudinal flange pairs connected toeach other in direct contact with the hollow cylindrical or hollowtruncated cone-shaped tube may include seam preparation.

Optionally, before separating the tower shell fixing means for securingthe shape of the tower shell may be attached.

According to one aspect, separating the tower shell into at least twocomponents may be done by sawing, milling, lasing, water jet cutting,burn-cutting or eroding.

Optionally, after detaching the longitudinal flange pair a furtherwelding process and/or weld reworking may be executed.

Additionally, joining the at least two components at the set-up locationof the tower may be done by screwing, riveting, jamming and/or weldingalong the longitudinal flanges.

Features disclosed in the above description, the following claims andthe included figures may both individually and also in any combinationbe implemented and of importance for the realization of an example indifferent implementations.

Although some aspects were described in connection with a device, it isobvious that these objects may also represent a description of acorresponding method, so that a block or a member of a device may alsobe regarded as a corresponding process or as a feature of a process.Analogously, aspects described in the context of or as a process alsorepresent a description of a corresponding block or detail or feature ofa corresponding device.

One example may thus be implemented as a program comprising a programcode for executing a method according to one example, when the programis executed on a programmable hardware component. The individualprocesses may here be acquired by controlling corresponding actuators,reading out memory locations or other data sources, numeric and othermanipulations of data and other processes. Within the scope of such aprogram but also within the scope of different implementations of amethod according to one example, the individual processes may thus, forexample, include generating, providing and, if applicable, receivingcontrol signals, sensor signals and other signals. Transmitting may alsoinclude writing or storing a value into a memory location or a register.Accordingly, reading out or receiving may also include a correspondingreading out of a register or a memory location. These signals may, forexample, be transmitted as electrical, optical or radio-technicalsignals and be implemented continuously or discretely independent fromone another regarding their signal values and their temporalimplementation. The corresponding signals may, for example, includeanalog signals but also digital signals.

The above described examples merely represent an illustration of theprinciples of the present invention. It is obvious that modificationsand variations of the arrangements and details described herein areobvious for other persons skilled in the art. It is intended that theinvention is only limited by the scope of the following claims and notby the specific details which were presented herein using thedescription and the explanation of the examples herein.

Features disclosed in the above description, the following claims andthe included figures may both individually and also in any combinationbe implemented and of importance for the realization of an example indifferent implementations.

REFERENCE SIGNS

-   100 subsection of a tower section-   102 subsection of a tower section-   106 contacting plane-   120 shell, shell segment-   130 longitudinal flange-   132 part of a surface contour of the longitudinal flange-   134 connecting surface-   136 contact surface-   138 hole-   150 longitudinal flange-   160 sealing element-   200 wind turbine-   210 tower section-   220 tower section-   230 machine house-   240 rotor-   300 method for manufacturing at least one subsection-   310 mounting two neighboring longitudinal flanges-   320 separating the shell-   402 gap between longitudinal flanges-   404 gap between shell segments-   432 location arranged facing the contact surface of the longitudinal    flange-   433 welding seam-   434 location arranged facing away from the contact surface of the    longitudinal flange-   435 welding seam-   438 screw-   460 transversal flange-   462 hole-   610 separating tool-   700 method for manufacturing a tower section-   710 mounting a first one-piece longitudinal flange-   720 detachably connecting a second one-piece longitudinal flange of    a second subsection of the tower section to the first one-piece    longitudinal flange-   730 mounting the second one-piece longitudinal flange-   740 separating the shell

1. A tower comprising a plurality of tower sections, wherein at leastone tower section comprises at least two subsections, wherein the atleast two subsections each include at least one longitudinal flangeconnected to a shell segment of the tower section, wherein a one-piecelongitudinal flange of a first subsection of the at least twosubsections is directly connected to a one-piece longitudinal flange ofa second subsection of the at least two subsections, wherein a gapexists between the shell segment of the first subsection and the shellsegment of the second subsection, wherein a gap exists between ends ofthe two neighboring, one-piece longitudinal flanges facing the shellsegments, wherein the gap between the two neighboring, one-piecelongitudinal flanges is larger than the gap between the shell segmentsof the at least two subsections.
 2. The tower according to claim 1,wherein the first subsection of the tower section comprises theone-piece longitudinal flange mounted to a longitudinal side of theshell segment for connecting to the longitudinal flange of the secondsubsection of the tower section, wherein the one-piece longitudinalflange of the first subsection comprises a part of a surface contourextending from a contact surface of the longitudinal flange of the firstsubsection which is provided for a connection to the longitudinal flangeof the second subsection to a connecting surface connected to the shellsegment of the first subsection, wherein the part of the surface contourcomprises a distance to a contacting plane passing through the contactsurface.
 3. The tower according to claim 2, wherein the part of thesurface contour of the longitudinal flange forms a notch or anundercut-shaped recess.
 4. The tower according to claim 2, wherein thepart of the surface contour of the longitudinal flange comprises adistance of more than 1.5 mm to the contacting plane at one end adjacentto the connecting surface connected to the shell segment.
 5. The toweraccording to claim 1, wherein the shell segment of the first subsectioncomprises a shape which substantially forms part of a cylinderbarrel-shaped or truncated cone jacket-shaped geometry.
 6. The toweraccording to claim 1, wherein the gap between the two neighboringlongitudinal flanges is more than 5 mm larger than the gap between theshell segments of the at least two subsections.
 7. A wind turbinecomprising a tower according to claim
 1. 8. A method for manufacturingat least a subsection of a tower section, the method comprising:mounting two neighboring, one-piece longitudinal flanges to a shell of atower section, so that the two neighboring, one-piece longitudinalflanges are directly in contact with one another along a contactsurface; and separating the shell at least along the two neighboring,one-piece longitudinal flanges, wherein a gap exists between the ends ofthe two neighboring, one-piece longitudinal flanges after mounting andbefore separating at the ends of the two neighboring, one-piecelongitudinal flanges facing the shell.
 9. The method according to claim8, wherein the two neighboring longitudinal flanges are connected toeach other by a detachable connection during separation of the shell.10. A method for manufacturing a tower section, the method comprising:mounting a first one-piece longitudinal flange of a first subsection ofa tower section to a shell of the tower section; detachably connecting asecond one-piece longitudinal flange of a second subsection of the towersection to the first one-piece longitudinal flange of the firstsubsection after mounting the first one-piece longitudinal flange of thefirst subsection to the shell of the tower section, so that the twoneighboring, one-piece longitudinal flanges are directly in contact withone another along a contact surface; mounting the second one-piecelongitudinal flange of the second subsection of the tower section to theshell of the tower section after detachably connecting the secondone-piece longitudinal flange of the second subsection of the towersection to the first one-piece longitudinal flange of the firstsubsection; and separating the shell at least along the two neighboring,one-piece longitudinal flanges, wherein at least after the separation agap exists at the two neighboring, one-piece longitudinal flangesbetween the ends of the two neighboring, one-piece longitudinal flangesfacing the shell.
 11. The method according to claim 10, wherein the gapexists between the ends of the two neighboring, one-piece longitudinalflanges after mounting the second one-piece longitudinal flange andbefore separating at the ends of the two neighboring, one-piecelongitudinal flanges facing the shell or wherein the shell is separatedsuch that after separating the gap exists at the ends of the twoneighboring, one-piece longitudinal flanges facing the shell between theends of the two neighboring, one-piece longitudinal flanges.
 12. Themethod according to claim 10, further comprising detaching thedetachable connection between the two neighboring, one-piecelongitudinal flanges for transporting to a destination of the tower. 13.The method according to claim 10, wherein before mounting to the shellthe one-piece longitudinal flange of the first subsection comprises apart of a surface contour extending from a contact surface of thelongitudinal flange of the first subsection which is provided for aconnection to the longitudinal flange of the second subsection to aconnecting surface connected to the shell of the tower section. whereinthe part of the surface contour comprises a distance to a contactingplane passing through the contact surface.
 14. The method according toclaim 10, wherein during mounting to the shell the one-piecelongitudinal flange of the first subsection is mounted to the shell by awelding seam at a side facing away from the second longitudinal flangeand at a side facing the second longitudinal flange.
 15. The methodaccording to claim 10, wherein during mounting to the shell theone-piece longitudinal flange of the second subsection is mounted to theshell by a welding seam at a side facing away from the firstlongitudinal flange.
 16. The method according to claim 15, wherein afterseparating the shell and after detaching the detachable connection, theone-piece longitudinal flange of the second subsection is additionallymounted to the shell by a welding seam at a side facing the firstlongitudinal flange.